Button actuated mechanism for a dispensing canister

ABSTRACT

An actuating mechanism for aerosol product dispensing containers, and more particularly to a button actuated aerosol spray valve actuating mechanism for actuating an aerosol spray valve and dispensing the aerosol product from the dispensing container.

FIELD OF THE INVENTION

This invention relates to an actuating mechanism for aerosol product dispensing containers, and more particularly to a button actuated aerosol spray valve actuating mechanism for actuating an aerosol spray valve and dispensing the aerosol product from the dispensing container.

BACKGROUND OF THE INVENTION

Aerosol dispensing containers generally comprise a pressurized canister within which is stored a product to be dispensed as an aerosol. The canister is pressurized, for example, by a propellant which is generally dissolved within the product. The product is released from the canister upon opening of, for example, a pressure actuated valve mechanism located in the top of the canister.

The valve mechanism generally comprises a valve stem defining a passage therethrough which communicates with the interior of the canister, and through which product may flow out of the canister when the valve is appropriately actuated. An orifice is often provided in the wall of the valve stem to provide access from the interior of the container to the passage. The valve stem is normally spring biased to a position in which the orifice is blocked or sealed so the product cannot enter the passage in the valve stem. A valve actuation assembly is generally mounted to the top of a canister to over lie, engage with and actuate the valve stem. When the actuation assembly is appropriately triggered, the valve actuation assembly depresses or tilts the valve stem against the biasing force to unblock the orifice and allow the pressurized aerosol product within the canister to enter the passage in the valve stem.

Typically, the actuator assembly includes a body or housing which is affixed to the top of the canister and an actuator plunger or button is fitted within the housing. The plunger or button generally fits over or within the body in some manner and connects with or at least indirectly engages or actuates the valve stem. A product passage is generally provided for guiding the released aerosol spray out of the spray can and through the valve actuation assembly to the environment. The product passage can be integral with either the body or the button or even be a separate structure which communicates between the valve stem and a product dispensing orifice formed in the actuator.

When the button is depressed by a user, the valve stem is depressed or tilted and as the valve stem is depressed or tilted, the orifice within the valve stem is moved away from the seal and the pressure within the dispensing canister pushes the aerosol product up through the orifice into the valve stem and hence into the passage and then into the product passage. Finally, the product is dispensed via a nozzle out the dispensing orifice.

After dispensing the desired amount of product, the button is released. The spring bias within the valve mechanism provides the restoring or biasing force to return the valve stem to the closed position in which the orifice in the valve stem is sealed and aerosol product is no longer permitted to be dispensed. Currently, known actuators of this type include many small parts which must be separately molded and then assembled. Obviously, the more parts which must be molded the more expensive the manufacture and assembly of such actuators becomes. Actuators are also known which attempt to reduce the number of separate parts which must be molded and assembled, however, such actuators tend to be intricate, complicated moldings and are particularly difficult and expensive to mold.

SUMMARY OF THE INVENTION

The present invention provides a spray actuator for a pressurized aerosol canister that overcomes certain shortcomings of prior art actuators and, in particular, button actuated spray actuators. Because of their functionality, button actuated spray actuators are composed of numerous parts which are, firstly, very difficult to mold and, secondly, and perhaps more importantly, difficult to assemble. The present invention simplifies the mechanical moving parts of a spray actuator to a body and a button and finally a third nozzle piece being inserted at the very end of the product dispensing passage either in the body or the button. Thus, there are only three separately molded parts to the present invention one of which includes the moveable button portion.

The moveable button rotates about a pivot or hinge point and is biased by engagement with the valve stem into a neutral unactuated position where the product is not dispensed. When dispensing of the product is desired, the user grasps the actuator and presses the button overcoming the bias of the valve stem and the valve is actuated as discussed above to dispense the pressurized aerosol product.

It is an object of the present invention to provide an economical and easy to manufacture and assemble spray actuator with a minimum number of parts and simple functionality.

It is a further object of the invention to provide a spray actuator which can be ergonomically actuated by one hand.

It is a still further object of the present invention to provide a spray actuator which requires minimal assembly and only three (3) separate molded parts.

The present invention relates to a spray actuator for an aerosol container comprising a body having an inner wall including an engagement collar for attachment to an aerosol container, a bottom edge for smoothly transitioning to and substantially contacting a sidewall of the aerosol container and, a top edge for supporting an actuator cap, a button integrally, hingedly attached to the actuator cap about a living hinge positioned between a static portion of the actuator cap and a moveable portion of the actuator cap defining the button, and wherein the static portion of the actuator cap is fixedly, immovably supported on the body, and the button is free to move relative to the static portion and the body, and the actuator cap pushes a product passageway integrally connected to one of the actuator cap and the body against a valve stem to actuate a valve of the aerosol container.

The invention also relates to a method of making an actuator for dispensing an aerosol product from an aerosol container, the method comprising the steps of forming a body having an inner wall including an engagement collar for attachment to an aerosol container, a bottom edge for smoothly transitioning to and substantially contacting a sidewall of the aerosol container and, a top edge for supporting an actuator cap, hinging a button integrally attached to the actuator cap about a living hinge positioned between a static portion of the actuator cap and a moveable portion of the actuator cap defining the button, and affixing the static portion of the actuator cap immovably supported on the body, and the button is free to move relative to the static portion and the body, and the actuator cap pushes a product passageway integrally connected to one of the actuator cap and the body against a valve stem to actuate a valve of the aerosol container.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an elevational perspective view of a spray can having the spray actuator affixed to the top of the spray can;

FIG. 2 is an elevational cross-section of the top of the spray can and supported spray actuator;

FIG. 3 is an further elevational cross-section of the top of the spray can and supported spray actuator;;

FIG. 4A, 4B are rear and side perspective views respectively of the body of the spray actuator;

FIG. 5 is a cross sectional view of the actuator body;

FIG. 6 is a perspective view of and undersurface of the button cap;

FIG. 7 is a perspective view of a side and top surface of the button cap;

FIG. 8 is a front perspective view of a second embodiment of the spray actuator;

FIG. 9 is an elevational perspective view of the actuator body of the second embodiment;

FIG. 10 is a rear cross-sectional view of the actuator body;

FIG. 11 is a cross-sectional side view of the actuator body;

FIG. 12 is a perspective top view detailing the interior of the actuator body;

FIG. 13 is a side perspective view of the second embodiment;

FIG. 14 is a cross-sectional side view of the second embodiment;

FIG. 15 is a perspective view of the button cap of the second embodiment;

FIG. 16 is a side elevational view of the button cap;

FIG. 17 is a cross-sectional side view of the button cap; and

FIG. 18 is a rear cross sectional view of the button cap.

FIG. 19 is a perspective side view of a third embodiment of the actuator and spray can;

FIG. 20 is a side elevational view of the third embodiment of the actuator and spray can;

FIG. 21 is a cross sectional side view of the actuator of the third embodiment;

FIG. 22 is a perspective view of the body of the actuator;

FIG. 23 is a cross sectional side view of the body of the actuator;

FIG. 24 is a perspective view of the actuator cap according to the third embodiment;

FIG. 25 is a perspective bottom view of the actuator cap of the third embodiment;

FIG. 26 is a bottom plane view of the actuator cap;

FIG. 27 is a cross sectional side view of the actuator cap of the third embodiment;

DETAILED DESCRIPTION OF THE INVENTION

An embodiment of the present invention is shown in FIGS. 1 to 7 as an aerosol spray actuator mechanism 1 for use in conjunction with a pressurized aerosol spray can C. The actuator mechanism 1 is comprised of three separately molded elements, a main body 3, a button cap 5, and a nozzle 7 as described in further detail below.

The main body 3 shown separately in FIGS. 4A-B and 5, is a hollow, substantially cylindrical, or conical shell having a sidewall 8 which slightly tapers from a bottom end 9 for engaging the aerosol can C to a top end 11 for supporting the button cap 5. The sidewall 8 is defined about a longitudinal axis A passing through the approximate center of the actuator 1 and the valve stem of the pressurized canister. The taper may include a waist portion 10 which has a smaller diameter than the remainder of the main body 3 relative to the axis A to provide ergonomic grasping of the actuator 1.

As seen in FIGS. 4A, 4B and 5, the top edge 15 of the body 3 is formed having a semi-circular rear notch 16 in a rear portion of the side wall 8 to allow for the actuation of the button cap 5 as will be discussed in further detail below. Between the top edge 15 and the bottom edge 13, the sidewall 8 varies in radial dimensions to facilitate ergonomic grippability and actuation of the button cap 5. It is to be appreciated that a moderately tapered hourglass-shape defining a waist portion 10 in the sidewall 8 between the top and bottom edges 15, 13 may facilitate a user's grasping the body 3 to actuate the spray mechanism 1, but that the body 3 could also be more or less cylindrical, i.e., having a generally constant radius about a vertical axis, depending upon desired ergonomic and aesthetic design characteristics.

As shown in FIGS. 4A-B, at least two pins 31 project vertically upwards from a sloping inner wall of the top end 11 of the body 3. The pair of front pins 31 protrude from an inside surface of the body 3 on opposing sides of the integral product passageway 21 formed with the body 3. The pins 31 extend relatively vertically upwards and slightly above the top edge 15 of the body 3 and are formed to receive corresponding engagement holes or posts 45 formed in the button cap 5 which, as will be explained in further detail below, detachably lock into the pins 31. The pins 31, as shown, have a generally uniform crossed cross-sectional shape, however, the pins 31 may take any shape necessary to facilitate the engagement of the pins 31 with the corresponding engagement holes in the button cap 5.

Further down and closer to the bottom end 9 on the inner surface of the body 3, as seen in FIG. 5, a circumferential retention lip 18 or axially adjacent retention lips are located near the bottom end 9 of the inner surface of the body 3. The retention lip 18 is generally a slight, substantially horizontal protrusion extending radially inwardly from the inner wall of the body 3 towards the center of the body 3. The retention lip 18 is sized so as to be slightly smaller in diameter and demountably engagable, i.e., snap-fit, with a rim or mounting cup M (shown in FIG. 3) of the aerosol can C to hold the body 3 and necessarily the actuator 1 in place and/or to prevent the aerosol can C from being inserted too far into the body 3. The retention lip 18 may be rounded projections, a ledge or some combination of the such elements capable of retaining the actuator 1 on the rim or mounting cup M of the spray can C.

Observing FIGS. 2 and 3, a product passageway 21 through which the aerosol can C disperses its contents is integrally molded into the body 3. The passageway 21 consists of a vertical inlet passage 23 and an outlet passage 25. The inlet passage 23 is substantially cylindrical and extends from a mating engagement with a valve stem S of the aerosol can C to an intersection with the outlet passage 25. A receiving portion 27 in the free end of the inlet passage 23 generally has a larger inner diameter than the remaining inlet passage so as to accept the valve stem S of the aerosol can C and define a downward facing ledge to provide the contact force on the valve stem S necessary for the aerosol can C to disperse its contents.

Observing FIGS. 4A-B and 5, on the outer surface of the inlet passage 23, an actuating element is defined, in the present embodiment, by two cam followers 35 or protrusions located on opposite sides of the inlet passage 23 from one another. The actuating element is generally acted upon by the button cap 5 or some appendage of the button cap 5 so as to force the inlet passage 23 downwards onto the valve stem S. In the present embodiment, a pair of appendages 46 (as seen in FIG. 6) having a cam surface 39 on a free end thereof depend downwards from the button cap 5 to engage the cam followers 35 and provide for a compressive force to be transferred from the button cap 5 to the inlet passage 23 to the valve stem S, thus causing the receiving portion 27 to depress the valve stem S of the aerosol can C which, in turn, dispenses the contents of the aerosol can C.

The outlet passage 25 of the product passageway 21 leads from the connection with the inlet passage 23 to a dispensing orifice 41 best seen in FIG. 5, usually having a mechanical breakup formed therein to assist in the aerosolizing of the dispensed product. The dispensing orifice 41 is sized to receive the third separate element of the actuator 1, the nozzle 7, which disperses the contents of the aerosol can C to the local environment. The dispensing orifice 41 is integrally connected with the sidewall of the body so that the integral connection between these two element flexes to permit the product passageway 21 to be rotated or bent relative to the body 3. The flex, rotation or bending provides for the product passageway 21 to actuate the valve V in the spray can C and dispense pressurized product from the spray can C into the product passageway 21.

The dispensing orifice 41 has a larger inner diameter than the outlet passage 25 so as to accept the nozzle 7, i.e., the third separate piece of the actuator construction. The nozzle 7 is, of course, inserted into the dispensing orifice 41 at the end of the outlet passage 25 after the body 3 is molded. The nozzle 7 may be a press fit circular piece having an outer diameter substantially the same as an inner diameter of the dispensing orifice 41 so as to be fixedly supported within this orifice when pressed in. The nozzle 7 generally has some type of narrowing aperture to cause acceleration and define a particular desired outward spray of the aerosol product from the dispensing spray can C.

Observing FIGS. 6 and 7, the button cap 5 is the element of the actuator 1 which provides for direct actuation, for example, by a finger or a thumb of the actuator 1. The button cap 5 is a single molded piece that secures over the top edge 15 and onto the main body 3. A front portion 42 of the button cap 5 is secured to the main body 3, and a rear portion 44 of the button cap 5 is not secured directly to the main body 3 but is, in fact, connected to the front portion 42 by a living hinge 48 and is moveable or rotatable relative to both the front portion 42 and the main body 3.

An underside surface of the front portion 42 of the button cap 5 includes two engagement holes or posts 45 having cavities 47 which engage the two pins 31 extending from the body 3. As best seen in FIG. 7, The rear portion 44 of the button cap 5 defines a relatively moveable top button surface 43 which has an underside surface from which depend the appendages 46 and cam surfaces 39 on the free ends of the appendages 46. The appendages 46 depend downward from the underside of the button surface 43 and are positioned in such a manner as to contact the cam followers 35 or protrusions on the inlet passage 23 of the product passageway 21.

The rear portion 44 of the button cap 5 which defines the button surface 43 is integrally attached to the front portion 42 of the button cap 5 by the living hinge 48 defined by a series of intermediately positioned channels 49 in the button cap 5. The channels 49 extend inwards from an outer edge of the button cap 5 to partially separate the front portion 42 of the button cap 5 from the rear portion 44 and define, by the material between the ends of the channels 49, the living hinge 48. When the pins 31 on the body 3 are inserted into the posts on the underside of the front portion 42, the button cap 5 is held in place on the top edge 15 of the body 3, i.e. the bottom outside edge of the button cap 5 is abutted against the top edge 15 of the body so that the body and the button cap form a substantially contiguous unbroken outer surface of the actuator. As this occurs, the cam surfaces 39 on the free ends of the appendages 46 are positioned against the cam followers 35 on the inlet passage 23 as previously described.

Observing FIG. 7, the outer edge of the rear portion of the button cap 5 is contoured so as to generally conform to, although it is slightly separated therefrom, the notch 16 formed in the rear portion 44 of the sidewall 8 of the body 3 as best seen in FIGS. 1, 2 and 3. This permits sufficient freedom of movement for the rear portion 44 of the button cap 5 to be depressed relative to the body 3.

The appendages 46 are shown as substantially rectangular parallel protrusions depending from the underside of the button cap 5. The appendages 46 extend to contact the cam followers 35 on the inlet passage 23 of the product passageway 21. It is to be appreciated that the appendages 46 may be of any form or shape which depend generally downward to engage some portion of the product passageway 21 and transfer force from the button surface 43 of the button cap 5 to actuate the valve V in the spray can C.

In the present embodiment, the appendages 46 are spaced apart so that there is sufficient space between them for the product passage 21, yet the appendages 46 must engage the cam followers 35 which extend only slightly from the vertical passage. The cam surfaces 39 are angled such that when the button cap 5 is affixed to the body 3 by inserting the pins 31 into the posts, the cam surfaces 39 on the appendages 46 are positioned substantially normal to the cam followers 35 on the product passage 21. Thus, the appendages 46 depress the product passageway 21 down onto the valve stem S. It is also possible to angle the cam surfaces 39 so that the inlet passage 23 is pushed in a desired direction, e.g., downward, or to the side to effect a tilting of the valve stem S and valve V.

When a force is placed on the button surface 43 of the button cap 5, a substantially downward or alternatively tilting force is thus placed on the cam followers 35, thus placing a relative downward or tilting force on the valve stem S of the aerosol can C to actuate the valve and dispense the pressurized product.

Turning to FIG. 7, the rear portion 44 of the button cap 5 is connected to the front portion by the living hinge 48 or a small section of material contiguous with the front and rear portions of the button cap 5. Therefore, when the front portion of the button cap 5 is held in place by the intersecting pins 31 and posts 45 and a downward force, such as a person depressing the button surface 43, is placed on the back portion, the living hinge 48 allows the back portion to rotate slightly, sufficient enough to cause the valve stem S of the aerosol can C to be depressed or tilted and disperse its contents.

FIGS. 8-18 relate to another embodiment of an actuator 51 also having three separate parts, a main body 53, a button cap 55 and a nozzle 57. The body 53, shown separately in FIGS. 9-12, is a hollow plastic substantially cylindrical or conical shell having a sidewall, which slightly tapers from a bottom end 59 for engaging the aerosol can C through a narrower intermediate waist portion 79, to a top end 61. The top end 61 is defined by a top edge 65 defining a top opening 67 and the bottom end 59 is similarly defined by a bottom edge 63 defining a bottom opening 69.

As seen in FIG. 12, the top edge 65 of the body 53 is formed having a semi-circular notch 77 in a front side wall to allow for a nozzle 57 and product passageway 71, which will be discussed in further detail below. From the top edge 65, the sidewall necks radially inwardly and downwards to define the radially narrower, intermediate waist portion 79. The waist portion 79 has a smaller diameter than the rest of the sidewall 8 relative to axis A through the actuator 51 to facilitate grasping of the actuator 51. The sidewall 8 then expands radially outwardly again continuing downwards to form the bottom end 59 of the body 53 thus defining the substantially hourglass-shape of the body 53. It is to be appreciated that the hourglass-shape may facilitate a user's grasping the body 53 to actuate the spray mechanism but that the body 53 could also be more or less cylindrical depending upon desired ergonomic and aesthetic design characteristics.

Four pins 81 project vertically upwards from a sloping inner wall of the top end 61 of the body 53. A pair of front pins 81 protrude from the inside surface of the skirt on opposing sides of the semi-circular notch and a pair of opposing rear pins also extend from a rear portion of the top end 61. The pins 81 extend upwards and slightly above the top edge 65 of the body 53 and are formed to receive an engagement hole or post 89 formed in the button cap 55 which, as will be explained in further detail below, detachably locks into the pins 81 to secure the button to the body 53. There may be any number of pins 81 to adequately secure the button cap 55 to the body 53. Also, the pins 81 are shown having a uniform cross-sectional shape, however, the pins 81 may take any shape necessary to facilitate the engagement of the pins 81 with the corresponding engagement holes in the button cap 55.

In FIGS. 10 and 11 a retention collar 78 for engaging the spray can C is shown on the inner sidewall of the body 53. The retention collar 78 is shown located substantially axially corresponding in relation with the intermediate waist portion 79 of the body 53, and comprises a lip or series of lips 83, and ledges 91. The retention lips 83 are slight substantially horizontal protrusions extending circumferentially about the vertical axis A of the actuator 51 from the inner wall of the body 53 towards the center of the body 53. The retention lips 83 are sized so as to “snap-fit” with, i.e., below, a rim 56 or mounting cup M of the aerosol can C to hold the body 53, and thereby actuator 51, in place. The ledge 91 positioned axially above the retention lips 83 is radially sized to rest on a top edge of the mounting cup M (as seen in FIG. 14) to prevent the aerosol can C from being inserted too far into the skirt. The retention lips 83 and ledge 91 may be rounded projections or a sharp edge, or any desired shape capable of retaining the actuator 51 on the mounting cup M and which are in relative proximity to one another to snugly grasp the edge of the mounting cup M.

The button cap 55 of the present embodiment shown in FIGS. 14-18 is an integrally molded structure comprising a circumferential cap rim 85 supporting an actuator button 58 and an integrally molded product passageway. On an undersurface of the cap rim 85 are provided four posts 89 defining engagement holes or cavities for engaging the pins 81 extending vertically from the body 53 as described above. The button cap 55 is positioned over the top edge 65 of the body 53 and the corresponding four post 89 and cavities are aligned and engaged to support or affix the cap rim 85 to the top end 61 of the body 53 as seen in FIG. 14.

Turning to FIG. 15, the actuator button 58 includes the integrally molded product passageway 71 therewith so that when a user presses down on the actuator button 58 which is substantially surrounded by and moveable relative to the cap rim 85, the product passageway 71 presses down on the valve stem S to the valve V and dispense the pressurized product from the aerosol spray can C. The actuator button 58 is connected to the cap rim 85, via a living actuator hinge 60, which allows the actuator button 58 and the integral product passageway 71 to move relative to the cap rim 85 to depress the valve stem S.

The product passageway 71 comprises an inlet passage 73 and an outlet passage 75, the outlet passage 75 further comprises a dispensing orifice 79 which communicates with the outlet passage 75 of the product passageway 71 and is sized to engage and support a separate nozzle piece. The inlet passage 73 communicates at a connection point with the outlet passage 75 and includes at a free end of the inlet passage 73 a slightly larger diameter passage designed to snugly engage the valve stem S and provide sufficient seal to depress the valve stem S when the actuator button 58 is actuated by a user. In the present embodiment, the button 58 is substantially completely surrounded by the cap rim 85 and connected to the cap rim 85 by the actuator hinge 60 generally located at a front portion of the button cap 55.

The cap rim 85 has an outer edge 93 which is contoured and sized to sleekly engage the top edge 65 of the main body 53 so as to present a substantially contiguous outer surface of the actuator 51 despite the separate parts. An inner edge 95 of the cap rim 85 is separate from, but generally aligned with an outer edge 97 of the actuator button 58, as seen in FIG. 18, except at the point of the actuator hinge 60. The actuator button outer rim 97 is spaced at a distance from the inner rim 95 where the button is close enough to present a substantially contiguous appearance while providing the necessary spacing to permit full actuation and movement of the actuator button 58 relative to the cap rim 85 and main body 53.

As seen in FIGS. 14-15 the dispensing orifice 79 is integral with the cap rim 85, i.e., the cap rim 85 also includes at least a portion of the dispensing orifice and a surrounding wall structure which is contiguous with the outlet passage 75. The surrounding wall structure is formed having an outer wall dimensions to fit within the front notch of the sidewall of the body 53.

It is to be appreciated that an integrally molded, return spring, e.g., a leaf spring (not shown) may also be integrally formed in the body 53 or on the button cap 55 or one of the parts thereof to assist in biasing the actuator button 58 into a non-actuated position. In other words, such a spring would ensure that after release of the actuator button after being depressed the button 58 is returned to a neutral position wherein the valve V is not actuated.

In a further embodiment of the present invention shown in FIGS. 19-27, another actuator 101 is shown in conjunction with a spray can C. As seen in FIGS. 19 and 20 similar to the previous embodiments, the actuator 101 comprises a body 103, an actuator cap 105 and a nozzle 107.

Observing FIG. 21 a product passageway 121 is formed integrally with the actuator cap 105, the product passageway 121 comprising a product inlet passage 123 and an outlet passage 125. The actuator cap 105 may be joined in a manner to the body 103 for instance by the respective posts and receiving holes as discussed with the previous embodiments, and not shown in the FIGS. 19-27 for purposes of clarity of the embodiment. In addition, the dispensing orifice 141 for receiving the nozzle 107 is shown formed integrally with the actuator cap 105 at the end of the outlet passage 125 of the product passageway 121.

As seen in FIGS. 22 and 23, tapered body 103 of the actuator 101 defines a waist portion 129 to facilitate the grippability of the actuator 101. A front notch 114 for receiving the dispensing orifice of the actuator cap a top edge 115 for supporting the actuator cap 105 and a rear notch 116 formed in the body 103 to provide clearance for relative movement of a button 158 of the actuator cap 105. Also on the inside surface of the body 103 is provided an engaging collar 178 for engagement with a mounting cup of the spray can C.

FIGS. 24 through 27 show the actuator cap 105 structure having a dispensing orifice 141 formed for receiving the nozzle 107. The actuator cap 105 having a static portion 142 and a relatively moveable portion 144 defining the button 158 for actuation of the valve in the spray can C. The relatively movable button 158 is defined by a first and a second channel 149 which each extend separately from the outer edge of the actuator cap 105 inwards to a respective first and second endpoints which are relatively spaced apart so as to define an amount of material therebetween defining a living hinge 148. Basically, the hinge 148 provides for flex or bending movement of the button relative to the static portion of the actuator cap 105.

Observing FIGS. 25-27 it is readily apparent that the product passageway 121 is substantially integrally molded on an underside of the moveable portion 144 defining the button 158 of the actuator cap 105. The downwardly depending portion of the product passageway 121 forming the inlet passage 123 engages with the valve stem (not shown) such that when a user depresses the button 158 the product passageway 121 presses on the valve stem and thus opens the valve and the actuator 101 dispenses product.

It should be appreciated that the outlet passage 125 of the product passageway 121 extends from the underside of the button, across the living hinge 148, and also connects with and forms the dispensing orifice 141 in the static portion of the actuator cap 105. The product passageway 121 is provided with sufficient sidewall material and flexibility so as to be able to withstand the flexing and moving of the product outlet 125 formed across the living hinge 148 during actuation of the button.

As seen in FIG. 27 the button is provided with a finger engaging surface 143 which is formed by a depression in the button 158. The button 158 also includes sidewalls 159 which depend downwards to substantially conform to the rear notch 116 formed in the body 103. The lower edge 160 defined by the sidewalls 159 is spaced from the top edge of the notch 116 in the body 103 a sufficient distance so as to not interfere when the button 158 is moved relative to the body 103 and the static portion 142 of the actuator cap 105.

Since certain changes may be made in the above described improvement, without departing from the spirit and scope of the invention herein involved, it is intended that all of the subject matter of the above description or shown in the accompanying drawings shall be interpreted merely as examples illustrating the inventive concept herein and shall not be construed as limiting the invention. 

1. A spray actuator for an aerosol container comprising: a body having an inner wall including an engagement collar for attachment to an aerosol container, a bottom edge for smoothly transitioning to and substantially contacting a sidewall of the aerosol container and, a top edge for supporting an actuator cap; a button integrally, hingedly attached to the actuator cap about a living hinge positioned between a static portion of the actuator cap and a moveable portion of the actuator cap defining the button; and wherein the static portion of the actuator cap is fixedly, immovably supported on the body, and the button is free to move relative to the static portion and the body, and the actuator cap pushes a product passageway integrally connected to one of the actuator cap and the body against a valve stem to actuate a valve of the aerosol container.
 2. The spray actuator as set forth in claim 1 wherein the product passageway defines a dispensing orifice in an outlet end of the product passageway integrally formed with one of the button and the body which communicates with a valve stem in the aerosol container.
 3. The spray actuator as set forth in claim 1 wherein the body further comprises at least an attachment point for fixedly engaging a mating point formed on the static portion of the actuator cap.
 4. The spray actuator as set forth in claim 3 wherein the static portion of the actuator cap extends circumferentially around the button.
 5. The spray actuator as set forth in claim 3 wherein the actuator cap further comprises a first channel and a separate second channel extending from an edge of the actuator button to respective first and second end points separated by an amount of material defining a living hinge between the button and the static portion of the actuator cap.
 6. The spray actuator as set forth in claim 5 wherein the button comprises an appendage depending from an underside of the button to contact and move a product passageway connected to the valve stem of the spray container.
 7. The spray actuator as set forth in claim 4 wherein the button further comprises an integral product passageway formed therewith which communicates between the valve stem and a product dispensing orifice.
 8. A spray actuator for an aerosol container consisting of 3 separate parts, a body, a nozzle, and an actuator cap comprising an integral button contiguously attached via a living hinge to a static portion of the actuating cap.
 9. The spray actuator as set forth in claim 8 wherein one of the actuator cap and the body further comprises an integrally formed product passageway communicating between a valve stem of the aerosol container and the nozzle.
 10. The spray actuator as set forth in claim 9 wherein at least a portion of the product passageway is aligned along a central vertical axis defined by the valve stem and the actuator cap and the body are axially fixed with respect to one another about the central vertical axis.
 11. The spray actuator as set forth in claim 3 wherein a bottom edge of the static portion of the actuator cap is supported directly on a top edge of the body so as to form a contiguous outer wall of the spray actuator.
 12. A method of making an actuator for dispensing an aerosol product from an aerosol container, the method comprising the steps of: forming a body having an inner wall including an engagement collar for attachment to an aerosol container, a bottom edge for smoothly transitioning to and substantially contacting a sidewall of the aerosol container and, a top edge for supporting an actuator cap; hinging a button integrally attached to the actuator cap about a living hinge positioned between a static portion of the actuator cap and a moveable portion of the actuator cap defining the button; and affixing the static portion of the actuator cap immovably supported on the body, and the button is free to move relative to the static portion and the body, and the actuator cap pushes a product passageway integrally connected to one of the actuator cap and the body against a valve stem to actuate a valve of the aerosol container. 